Methods and apparatus for making strands, rovings, yarns and the like



Jan. 25, 1966 F. KALWAITES 3,230,584

METHODS AND APPARATUS FOR MAKING STRANDS, ROVINGS, YARNS AND THE LIKEFiled March 5, 1964 4 SheetsSheet 1 INVENTOR Fem/K haw/r55 ATTORNEY Jan.25, 1966 F. KALWAITES 3,230,534

METHODS AND APPARATUS FOR MAKING STRANDS, ROVINGS, YARNS AND THE LIKE 4Sheets-Sheet 2 Filed March 5. 1964 INVENTOR Aka K 4741/;44/755 BY MM 7 MATTORNEY Jan. 25, 1966 F. KALWAITES METHODS AND APPARATUS FOR MAKINGSTRANDS, ROVINGS, YARNS AND THE LIKE 4 Sheets-Sheet 5 Filed March 5,1964 ATTORNEY Jan. 25, 1966 F. KALWAlTES TUS FOR MAKING STRANDS3,230,584 ROVINGS, YARNS METHODS AND APPARA AND THE LIKE 4 Sheets-Sheet4 Filed March 5, 1964 INVENTOR /?4/VA [41/144/755 [2,121. BY

fl nmm M4.

ATTORNEY United States Patent 3,230,584 METHODS AND APPARATUS FOR MAKINGSTRANDS, .ROVIN GS, YARNS AND THE LIKE Frank Kalwaites, Somerville,N.J., assignor to Johnson & Johnson, a corporation of New Jersey FiledMar. 5, 1964, Ser. No. 350,146 26 Claims, (Cl. 19-150) The presentapplication is a continuation-in-part of my co-pending applicationSerial No. 772,740, filed November 10, 1958, and now abandoned.

This invention relates to strands, rovings, yarns and the like and tonovel methods and apparatus for making the same.

In the conventional production of presently available commercial yarn,textile fibersare carded into a fibrous web which is drafted, made intorovings, or otherwise mechanically processed in a plurality of separatesteps, and then twisted or spun into yarn having sufficient strength andintegrity to be used in weaving, knitting, braiding, and like textilefabricating operations. The resulting twisted yarn ordinarily exhibitsan undesirably irregular and vvariable linear density, wherein thin,uneven and weak sections andthick, bulky portions are commonplace.Additionally, this twisted yarn is a compromise of many, antagonisticqualities, notably softness and strength, which are, usually inverselyrelated. In some cases, this compromise of qualities severely limits theusefulness of the twisted yarn, such as for example, when softness isdesirable but must be sacrificed for strength, or vice versa.

In co-pending, commonly-assigned patent applications Serial Numbers745,010 and 745,163, filed June 27, 1958, now US. Patents No. 3,135,023and No, 3,018,521, respectively, there are disclosed methods andapparatus for making strands, yarns and the like involving, inter alia,the application of fluid rearranging forces, including a combination ofliquid and pneumatic forces, to a layer of a fibrous starting materialwhereby it is divided and formed into strands having substantially,constant linear density, along with excellent softness and goodstrength. Such methods and apparatus have commercial practicability, andacceptable strand s, yarns, and the like, have been made employing theprinciples set forth in said patent applications. l

, It has now been discovered that the fibrous layer of starting materialmay be converted into a plurality of unitary strands by methods andapparatus employing pneumatic principles exclusively. Such methods andapparatus involve the passing of a gaseous medium, such as air, throughthe fibrous layer of starting material and during such passage dividingthe layer into a plurality of fibrous strips.

Portions of the gaseous medium arelaterally deflected in spaced,generally parallel zones so that they exert components of force on eachof the fibrous strips in directions generally parallel to the planethereof, whereby at least one of the sides of each of thefibrous stripsis individually rolled inwardly in substantially spirallywrapped fashionto form' unitary strands.

It has also been discovered that the conversion of the fibrous layer ofstarting material into a plurality of unitary strands is facilitated bydrafting the starting fibrous layer or otherwise increasing its degreeof fiber alignment with respect to the longitudinal axis of the fibrouslayer. This is accomplished, according to another .phase of the presentinventive concept, by forming a fibrous layer on a moving surface, suchas the peripheral surface of a rotating dolfing cylinder of acard, andthen removing the fibers therefrom and depositing them in pressingcontact 3,230,584 Patented J an. 25, 1966 Ice on another moving surface,such as an endless supporting screen or belt, which possesses a greatersurface linear speed than the surface from which the fibers are removed.In this way, the fibers are not only doifed from the forming surface andtransferred to a supporting carrier but are simultaneously drafted,whereby higher degrees of fiber parallelization and alignment areprovided to facilitate the strand formation. F

The starting web or layer which is processed to form the products ofthis invention may contain-natural or synthetic, vegetable, animal ormineral fibers such as cotton, silk, wool, vicuna, mohair, alpaca, flax,ramie, jute, abaca, etc.; synthetic or man-made fibers such as thecellulosic fibers, notably cuprammonium, viscose or regeneratedcellulose fibers; cross-linked cellulosic fibers such as Corval andTopel; cellulose ester fibers such as cellulose acetate (Celanese) andcellulose tri acetate (Arnel); the saponified cellulose ester fiberssuch as Fortisan and Fortisan-36; the polyamide fibers suchas nylon 420,nylon 6 (polycaprolactam), nylon 66 (hexamethylene diamine-adipic acid),nylon 610 (hexamethylene diamine-sebacic acid), nylon 11(l'l-amino'undecanoic 'acid-Rilsan);' protein fibers such as Vicar-a;

halogenated hydrocarbon fibers such as Teflon (polytetrafluoroethylene);hydrocarbon fibers such as poly: ethylene, polypropylene, polybutadiene,and polyisobutyl ene; polyester fibers such as Kode'l and Dacfo'n; vinylfibers such as Vinyon and saran; dinitrile fibers such as Darvan;nitrile fibers such as Zefran; acrylicfibers such as Dynel', Verel,Orlon, Acril-an, Creslan, etc.; mineral fibers such as glass, metal;etc.

The starting web may comprise either discontinuous fibers or continuousfibers, i.e. filamentary material. i If discontinuous fibers are usedin'the starting web the lengths of the fibers will vary from about /2inch up to about 2 /2 inches or more in length, depending upon theparticular properties and characteristics requiredor desired in theresulting strands. If desired, the fibrous layer may contain a minorproportion, less than about by weight and preferably less than about 25%by weight, of fibers other than those of textile length. These otherfibers may be of papermaking length, which extend from about /2 inchinlength down to about of an inch in length, which shorter fibersnormally cannot be used in conventional methods of producing strands oryarns.

7 less than about inch and down to about of an inch.

If continuous fibers are used in the starting web, e.g., a web of spreadtow, .any of the synthetic or made-made continuous filaments may beused, or any of the longer natural fibers, e.g., wool, vicu'na, etc.,which veryoften have lengths greater than 2 /2 inches may be used; Thecontinuous fiber webs used in accordance with the present invention havea high degree of orientation and there is little cross entanglement ofthe fibers.

The denier of the individual synthetic fibers, whether discontinuous orcontinuous, referred to above is pref-v erably in the range of'theapproximate thickness of the natural fibers mentioned and consequentlydeniers in the range of from about 1 to about 5 are preferred. Wheregreater opacity or greater covering power is desired, special fiberdeniers of down to about /1 or even about /2 may be employed. Wheredesired, denier-s of up to about 5.5, 6, 8, 10, 15, or higher, may beused. The minimum and maximum denier used are naturally dicrated by thedesires or requirements for producing a par- 3 ticular strand or yarn,by the machines and methods for producing the same, and so forth.

The weight of the fibrous web or layer of starting material may bevaried within relatively wide limits de-,

pending upon the requirements of the intermediate or the completedproducts. A single, thin web of fibers, such as produced by a card, .aspresented by the dofiing cylinder, may have a weight of from about 25 toabout 250 or more grains per square yard and may be used in theapplication of the principles of the present invention.

Furthermore, a single thin web of continuous filaments, such as producedby spreading a tow of continuous filaments into a wide sheet by usingfluid forces to spread the tow, may have a weight of from about 40 toabout 200 or more grains per square yard and may be used in theapplication of the principles of the present invention. Within the morecommercial aspects of the present invention, however, web Weights offrom about 50 grains per square yard to about 150 grains per square yardare contemplated.

It, of course, will be appreciated that the heavier the starting web is,the heavier will be the individual strands produced therefrom, assumingno change in the number of strands so produced. And, similarly, thegreater the number of strands produced from a starting web, the lowerwill be the weight of each individual strand so produced.

As will become evident from a consideration of the followingspecification, when the fibrous starting material is divided by thegaseous medium into a plurality of fibrous strips which, in turn, arerolled into unitary strands, the number and width of the fibrous stripsare determined principally by the nature, arrangement and orientation ofthe fibers in the starting layer, the freedom of movement of theindividual fibers as they are moved on'a supporting member, the physicalnature and intensity of the gaseous medium employed, the shape, size,and the spacing of the parallel zones in which the pneumatic forces areapplied by the gaseous medium, and the like.

The number and width of the fibrous strips which are converted intounitary strands affects the length of the individual fibers that may beemployed in the starting material as well as the degree of fiberalignment that should be present'in the starting material in order toavoid too many interconnecting cross fibers and to achieve substantiallyseparate strands as'the final prodnote. If the individual fibers in thestarting material are no longer than the distance separating the strandsproduced, the degree of alignment or parallelization of the fibers inthe starting material is relatively unimportant. However, when theindividual fiber length is greater than the distance between the strandsproduced, the degree of alignment of the fibers in the starting materialbecomes increasingly important as the length of the fibers increases. Ifit is desired to achieve substantial separation of adjacent strandswithout being required to sever any large number of interconnectingfibers, the degree of alignment or parallelization of the startingfi'bers must be higher when the fibers are longer.

A conventional card web as present on the dofi'ing cylinder of the cardmakes a suitable starting material for the application of thisinvention, particularly after it has been given some additional draftingor aligning over that produced by the carding machine. In such fibrouswebs, it is diificult to measure fiber orientation or alignment directlybecause the individual fibers thereof are curled, hooked and bent, withvarious segments of the fibers extending in various directions. A kindof average orientation which is helpful in describing the physicalcharacteristics of the web may be defined and experimentally measured.This physical characteristic is called the degree of fiber orientation,the degree of fiber alignment, or the percent of fiber parallelism. Thisdee or percent is determined by lightly bonding the web uniformly with amaterial such as starch, drying the bonded web, measuring tensilestrengths lengthwise and crosswise of the bonded web and then computingthe percentage of lengthwise or length-strength of the web to its totalstrength. Total strength, for this purpose, is the arithmetical sum ofthe tensile strengths in the long and cross directions. Thus, if thelong tensile strength in a conventional card web is 3 times the crosstensile strength, the degree of fiber orientation is 75%.

One skilled in the art who applies the teaching of this specification,will be able to examine a given starting fibrous layer and determinewhether the principles of this invention can be used to producesatisfactory strands connected by a minimum, if any, connecting fibers.In' making this determination, measurement of the degree of fiberorientation as defined above will be helpful.

When the fibers of the starting material are continuous there must belittle if any cross-over of the continuous fibers and virtually all ofthe continuous fibers must be substantially parallel to each other andrun in'the longitudinal direction of the starting web. When the fibersof the starting material are of fairly long textile length, say, about1% inches or over, the starting fibers should display an alignment of atleast about 90% or more in the longitudinal direction prior to theinitiation of strand formation. With fibers of medium textile length,say, from about inch to about 1% inches, a fibrous starting materialhaving about or more alignment will produce satisfactory strandproducts. If fibers of relatively short textile length, from about /2'inch to about /1 inch, are employed, a strating material of as low asabout 70% may be used.

The, invention will be more fully understood from the description whichfollows, taken in conjunction with the accompanying drawings in whichthere are illustrated preferred designs of machine and modes ofoperation embodying the invention. It is to be understood that theinvention is not to be considered limited to the constructions disclosedexcept as determined by the scope of the appended claims. In thefollowing drawings:

FIGURE 1 is a simplified, fragmentary, schematic per spective viewshowing the general principles of operation of the present invention;

FIG. 2 is a simplified, schematic cross-sectional view showing ingreater detail the construction of a vacuum box employed with thisinvention;

FIG. 3 is a simplified, schematic, fragmentary, ex-

. ploded perspective view of a part of the front end of the same vacuumbox;

FIG. 4 is a simplified, schematic view in plan of the vacuum box and itsassociated deflector forming plates and cooperating forming slots withthe fibrous web and strands-omitted for purposes'of clarity;

FIG. 5 is a simplified, schematic view in cross section, taken on theline 55 of FIG. 4, looking in the direction indicated, prior to theformation of the strands;

FIG. 6 is a simplified, schematic view in cross section, taken on theline 6-6 of FIG. 4, looking in the direction indicated, showing theinitial formation of the strand;

FIG. 7 is a simplified schematic view in cross section, taken on theline 77 of FIG. 4, looking in the direction indicated, showing theformation-of the strand at a later stage than that shown in FIG. 6;

FIG. 8 is a simplified, schematic view in cross section, taken on theline 8-8 of FIG. 4, looking in the direction. indicated, showing thestrand in substantially completed orm;

' FIG. 9 is a simplified, schematic, fragmentary view in, plan of amodification of the deflector forming plates and cooperating formingslots in the vacuum box;

FIG; 10 is a simplified, schematic view in cross section, taken on theline 10 -10 of FIG. 9, looking in the direc-- tion indicated, showing aninitial stage of the formation of the strand;

FIG. 11 is a simplified, schematic view in cross section, takenon theline 1111 of FIG. 9, looking in the direction indicated, showing anintermediate stage of formation of the strand;

FIG. 12 is a simplified, schematic view in cross section, taken on theline 12,12. of FIG. 9, looking in the direc tion indicated, showing thestrand in substantiallyv completed form;

FIG. 13 is a fragmentary perspective view in slightly exploded form,showing a strand product of the present invention; and

FIG. 14 is a fragmentary perspective view in slightly exploded form,showing another embodiment of the strand product of the presentinvention.

In the embodiment of the invention illustrated in FIGS. 1 to 81 of thedrawings, aconventional textile card comprisinga main cylinder 20 and aconventional dofling roll or cylinder 22 are shown in FIGS. 1. and 2 toprovide for the normal carding of the fibers fed to the card and theproducing of a thin, fibrous web on the dofiing cylinder. The directionsof rotation of the card and the doffing cylinder are as illustrated bythe directional arrows. Only a portion of the width of the main cylinder20 and dofting cylinder, 22 of the. card is illustrated and it is to beap preciated, that the actual width ofthe main cylinder and doffingcylinder is manytimes the width illustrated.

Immediately adjacent. the dofiing cylinder 22 and approximately at theposition where the fibrous web formed thereon is conventionally removedby the usual textile dofling means is a suction or vacuum box 24. Ahollow conduit or vacuum header 28, connected to asuitable suctiondevice (not shown), passes through the interior of the vacuum box24.and'provides the me'ans for withdrawing airfrom within the vacum box24, as well as constituting a supporting bracket therefor. The hollowvacuum header 28 is adjustably mounted in supporting brackets so thatthe nose portion 32 (best seen in FIG. 3) of the vacuum box can beaccurately positioned and spaced with respect to, theperiphery of therotating dofier cylinder 22 Such positioning and spacing is important tothe application of the present invention and is in the range of fromabout 0.005 inch to about 0.125 inch and preferably from about 0.015inch to about 0.030 inch.

As seen in FIG. 3, the sides of the vacuum box'24 are extended forwardlyabove and beyond the nose portion .32 thereof to form end flanges 34, 34in which elongated slots 36, 36 are provided to permit-the adjustableand accuratemounting of a guide nip roller 36 therein. Suitable lockingmeans (not shown) are provided for mounting and securing the guide niproller 36 in position properly adjusted with respect to the periphery ofthe doffing cylinder 22. The guide-nip roller 36 is positioned as closeas conveniently possible to the doffing cylinder 22 so as to provide aminimum of clearance and to facilitate the trans fer of a fibrous webfrom the dofling cylinder. This clearance will depend to some extentupon the weight of the web on thedofling cylinder, the nature and staplelength of the fibers in the fibrous web, etc., and in most cases, aclearance of from about 0.005 inch to about 0.125 inch, and preferablyfrom about 0.015 inch to about 0.030 inch has been found satisfactory.This distance, however, may be increased in particular situations wherethe web weight or type of fiber permit such an increase.

, A foraminous supporting screen or carrier 60, such asa nylon or wirebelt, is positioned so as to cover the nose portion 32 of the vacuum box24, pass under the'guide niproller 36, and then extend along the topsurface of the vacuum box 24. This foraminous supporting screen 60 isendless and moves in a complete cycle past the vacuum box 24 and itsnose portion 32 for a purpose to become clear. hereinafter.

Consideration of FIG. 2 will reveal that when air is drawn into thevacuum box 24 by the vacuum header 28 there will be suction or anegative pressure applied to the a, doffing cylinder to induce an airflow pastthe guide nip roller 36 and through the foraminous supportingscreen 60 into the vacuum box 24. This airflow is basically in two partswith one lowerpart passing between the guide.

nip roller 36- and the nose 32 of the vacuum box 24, and the other upperpart of the air flow passing between the guide nip-roller 36 and asupporting guide bracket 30.

The nose portion 32 of the vacuum box 24 is perforated, as illustratedin FIG. 3, to provide for a more even and uniform flow of air wherebythe fibers on the dofiing cylinder 22 are. removed therefrom and aredrawn in the direction of the vacuum box 24 at that location and arethus deposited, on the foraminous supporting screen 60. Both parts ofthe air flow referred to above pass through I the foraminous supportingscreen- 60 on their way into the vacuum box 24 and in so, doing hold inplace the fibers of the fibrous web, which are positioned on theforaminous screen.

The. upper surface of'the vacuum box-24 is open and a removable, slottedforming plate 38. is adapted to be positioned in such a way as to extendover this opening. A locking slot 40 is provided along the full length,of the supporting guide bracket 30; and is adapted to cooperate with alocking lip 42, which extends downwardly along the full length of theremovableforming-plate 3.8. The length of the forming plate 38 issufiicient to extend beyond thev rear edge of the opening in-the-uppersurface.

of the vacuum box 24 and to restupon the rear slanted edge thereof.

Forming slots 44 are provided in the top surface of the removable.forming plate-38 of the vacuum boxand provide openings'through which airmay be drawn into the vacuum box 24-by means of the vacuum header-28 andassociated suction means. As shownin FIGS. land 4, the forming slots 44extendgenerallyangularly along the length of the. formingplate- 38. butare slanted thereon with respect to the m'achinedirection to such anextentthat' thefopeningat the leading end of one. forming slot at leastcoincides with and preferably slightly overlaps the opening in thetrailing edge-of the adjacent slot, as determined by a line extending inthe machine direction.

An air deflector frame or open plate 46 (FIG. 1) comprising a forwardlypositioned support 48 and a rearwardly positioned support 50 isprovidedand may be positioned directly above the removable forming plate38 andthe, foraminous supporting screen 60. Legs 52, 52- are. provided so thatthe air deflector plate 46 is. accurately and sufficiently spaced fromand generally parallel to the removal forming plate 38 and theforaminous supporting screen 60. The legs 52, 52 of the air deflectorframe 46 reston the foraminous supporting screen 60 and are preventedfrom movement therewith by extension bars (not shown) which extendbeyond the sides of .the foraminous supporting screen 60 and are securedto a stationary structure, preferably the card frame itself. Deflectorstrips 54 are provided and extend from the forward support 48 to therearward support 50. As illustrated in FIG. 4, the air deflector strips54 extend generally in the machine direction but arev slanted slightlywith respect thereto so that their vertical projections generally fallupon and cover the forming slots 44.

The cross-sectional views'shown in FIGS. 6 through 8 illustrate therelationship of the air deflector strips 54 and the forming slots 44.The air deflector strips 54 are wider and longer than the forming slots44 and, as positioned, prevent the direct access of air into theseslots. Theileft hand edge of each deflector strip 54 (as seen in FIGS.6-8), is positioned substantially above the left-hand edge of eachforming slot 44, whereas the right-hand edge of each deflector strip 54is positioned well to the right-hand edge of each forming slot 44.

Although the terms right-hand and left-hand are used herein withreference to specific constructions utilizing the present invention, itis to be appreciated that such specific constructions are primarilyillustrative and could be readily reversed, in which case left-hand andright-hand descriptive terms would also be reversed.

The positioning of the air deflector strips 54 thus divides the flow ofair into the vacuum box into two basic components. The first of thesecomponents travels downwardly in substantially a vertical ornear-vertical direction beneath the left hand side of the air deflectorstrips 54, as viewed in FIGS. 6 through 8, and passes through theforaminous supporting screen 60 and then through the forming slots 44.This substantially vertical or nearvertical air flow exerts a forceagainst the layer, one component of such force being generallyperpendicular to the plane of the layer. This component tends to holdthe parts of the layer in position on the movable foraminous supportingscreen 60 which is interposed between the air deflector strips 54 andthe slotted forming plate 38 and,

which continuously moves past the forming slots 44.

The second component of the air flow passes to the right of and underthe air deflector strips 54 and, as illustrated by the directionalarrows, possesses a component of force which is generally horizontal andsubstantially parallel to the plane of the foraminous supporting screen60 and the web positioned thereon. This lair flow additionally isconcentrated and increased by the fact that the air is being funneledthrough the narrow opening created between the deflector strip and theforaminous screen. It is this increased air flow which, in passingangularly through the fibrous web, severs it and then, due to itshorizontal component of force, rolls it inwardly and in spiral fashioninto a untiary strand.

If desired, the air deflector strips may be slanted slightly upwardly,as shown in FIGS. 6 through 8. This angle may range from as low as aboutto as high as about 30 with respect to the plane of the forming plateand preferably from about to about 20.

It will thus be apparent (FIG. 2) that the fibrous web which is formedon the dofling cylinder 22 is removed from the periphery of suchcylinder by the vacuum sucking action at the nose portion 32 of thevacuum box 24. In this action, the fibrous web is deposited upon theforaminous supporting screen or carrier 60 which is interposed betweenthe vacuum box 24 and the dofling cylinder 22. The foraminous supportingscreen 60 moves onwardly carrying the fibrous web past the nose portion32,

left hand side of the air deflector strips, as described previously inconnection with FIGS. 4 through 8, and holds that portion of the fibrousweb in position. The laterally deflected portion of the air flowpenetrates the fibrous web in zones at the right edge of forming slots44 to divide the web into a plurality of fibrous strips. As the stripsmove onwardly in a machine direction along the forming plate 38 andunder the air deflector strips 54, the horizontal forces exerted by theair flow, in conjunction with the slanting and tapering configuration ofthese forming slots 44, is such that thesides of the divided fibrousstrips are individually rolled inwardly to form a plurality of unitarystrands. As is seen, the zone in which the air passes through thefibrous web is progressively shifted to the left in FIGS. 6 through 8 asthe fibrous web advances in the machine direction.

The precise operation is illustrated in FIGS. 5 through 8. In FIG. 5,the fibrous Web is illustrated in unitary, intact form, being carried bythe foraminous supporting screen 60 as it moves over the forming plate38 prior to its movement over the forming slots 44.

FIG. 6 illustrates the initial division of the fibrous web into a seriesof substantially parallel, divided fibrous strips. The positionillustrated is subsequent to the initial division of the fibrous web andshows the initial rolling inwardly of one side of each fibrous strip.

FIG. 7 illustrates the action at a later stage in which the formingslots 44 and deflector strips 54, and thus the zones to which thepassage of air through the fibrous layer is confined, have all moved tothe left of their original position and have enabled the fibrous stripto continue rolling to form a spirally wrapped unitary strand.

FIG. 8 illustrates the spirally wrapped, unitary strand S insubstantially completed form wherein the forming slots 44 and airdeflector strips 54 have moved to their farthest-left strand-formingposition. The completed :strand product S is illustrated in slightlyexploded form in FIG. 13 which clearly illustrates the spiral wrappingof the substantially parallelized or aligned fibers. Such a strandproduct S has excellent uniformity, substantially constant lineardensity and a minimum of thin, weak portions or thick, bulky sections.The individual fibers each lie in a spirally-shaped surface having-morethan one convolution and which is wrapped into a unitary strandconstruction. A plurality of spiral convolutions up to three, four ormore is obtainable if the, fibrous strips into which the card layer wasinitially subdivided are sufiiciently wide.

The foraminoussupporting screen moves beyond the end of the vacuum box24 and is directed downwardly (FIG. 1) carrying the strands S onwardlyto'conventional twisting devices, such as a flyer-twister (not shown) orother processing or treating means, asdesired.

A guide roll 62 is provided to direct the foraminous supporting screen60 upwardly, where it passes between suitably positioned tensioning andtracking rollers 64 and 66. Roll 66 may be adjusted vertically so as tocontrol the tension in the foraminous supporting screen 60. 7 Roll 64may be selectively and positively driven by a conventional'variablespeed device (such as a Reeves drive) which drives a belt 68 and pulley70 at any desired or required linear speed. A shaft 72 is provided totransmit the driving power from the driving pulley 70 to the drive roll64. In the event that a simpler, more direct drive is desired, guideroll 62 may be independently directly. driven from a source of power(not shown) as desired or required.

The foraminous supporting screen 60 1 is thus independently driven atasurface. linear speed which is at least equal to the surface peripheralspeed of the doffing cylinder 22, and preferably greater than thatspeed, in order to draft the fibrous web and increase its fiberorientation in the machine direction. This speed ratio of the foraminoussupporting screen 60 to the dotfing cylinder is preferably greater than1:1 and may be increased to 3:1 or 5:1 or

even higher depending upon the extent of the drafting desired or thefiber parallelism or alignment required. Within the more commercialaspects of the present invention, a speed ratio of from about 2:1 toabout 4:1 has been found most advantageous.

The importance of the positioning and size of the guide nip roll 36 isto be appreciated at this time. In order to properly draft the fiberswhich are to be dofied from the dofiing cylinder 22 by the suctionapplied at the nose portion of the vacuum box 24 and transferred to theconveyor belt 60, it is necessary that the distance between the point ofremoval of the fibers from the doffing cylinder 22 to the point ofpressing contact between the guide nip roll 36 and the conveyor belt 60be less than the average staple length of the fibers in the web. If thisdistance is greater than the average staple length of the fibers, thedrafting will be unsatisfactory for the purposes of the presentinvention.

The size of the guide nip roll is also an important considerationinasmuch as the use of the guide'nip roll which is too large willprevent its proper locating insofar as the critical distance between thepoint of fiber removal on the dofling cylinder and the gripping point ofthe dofl'ed fibers by the cooperating guide nip roll and the conveyorbelt is concerned. Use of too small a guide nip roller is also to becautioned against inasmuch as such 9 increases the tendency of the'doffed fibers to wrap thereabout and not transfer properly to theconveyor belt. The circumference of the guide nip roll should thereforebe greater than the average staple length of the fibers being dofied inorder to prevent such undesirable wrapping.

It is therefore seen that the drafting of the fibers is accomplished bythe greater linear speed of the conveyor belt on and the cooperating niproll 36, as compared to the lesser peripheral linear speed of thedoffing cylinder 22, taken .in conjunction with the grip on the fibersby the guide nip roll 36 and the conveyor belt 60, as the fibers aredoffed from the dofiing cylinder;

The guide nip roll 36 possesses an additional function of providing forthe removal of the dotted fibers from the peripheral surface of thedoffing cylinder at a very sharp angle of depa-rturewhich usually isgreater than 45 and approaches 90in many cases (see FIG. 2). In thisway, the dotted fibrous web is quickly and more reliably removed fromthedofling cylinder and is likely to drift back to the dofling cylinder asit would tend to do if the angle of departure were low. Measurement ofthe angle of departure is very difiicult inasmuch as the surface of theconveyor belt and the surface of the dofling cylinder are theoreticallytangential at their point of proximity but an understanding .is obtainedfrom FIG. 3 wherein it is noted that the conveyor belt is very quicklycurved from a convex configuration to a concave configuration by theguide nip roll whereby the sharpness of the departure angleis increasedrapidly. Additionally, the guide nip roller 36 promptly grips the fibersand presses them adheringly against the conveyor belt 64 thereby makingthe frictional engagement of the fibers with the conveyor belt moresecure to decrease even further the possibility of their drifting backto the doffing cylinder.

Another aspect of the present inventive concept is to be noted at thistime in that the foraminous supporting screen 66, if driven at a surfacelinear speed which is lessthan the surface peripheral speed of thedoifing cylinder 22, will condense the fibrous web and increase itsdensity (grains per square yard) and simultaneously decrease its fiberorientation in the long or machine direction. The use of such lowerratios, which may be as low as' 1:2, 1:3 or less, increases theisotropic characteristics of the web to a point wherein substantially anisotropic fibrous web containing fibers substantially at random may beobtained. Such an isotropic web, although not useful for the preparationof strands, rovings, yarns and the like in accordance with the presentinvention, possesses many other uses for which isotropic characteristicsare desired. It is therefore seen that apparatus and methods areprovided according to the. present inventive concept of changing thefiber orientation of the fibrous web, eitherto an increased or adecreased degree, simultaneously with its removal from the surface uponwhich it is formed.

In PEG. 9, there is illustrated a modification of the forming plate andcooperating forming slots which utilizes the same pneumatic principlespreviously described. A forming plate 138 is provided which fits uponand rests upon the upper surface of a vacuum box similar to vacuum box24. The forming slots 144, however, are bifurcated and somewhatgenerally having a slanting Y-configuration comprising a tapered baseportion 143 and angularly extending arms. 145 and 147. Short extensions149 and 151 are provided at the ends of the arms 145 and 147,respectively, and extend substantially in the machine direction or thedirection of predominant orientation of the fibers in the starting web.

v A foraminous supporting screen 160 which is similar in constructionand operation to previously-described fora-ruinous supporting screen 60is provided and moves along upon the surface of the forming plate 138.Positioned above the foraminous supporting screen 160 is an airdeflector plate 146 which is similar in operation and function to airdeflector plate 46. The main difference between the air deflector plate146 and the air deflector plate 46 is that the air deflector plate 146is formed in a one-piece integral construction. .It is basicallysimilar, however, and also has a forwardly positioned support 148 and arearwardly positioned support 15f) and connecting deflector strips 154.

As noted in FIG. 9, the air deflector strips 154 have a forwardlyextending portion 153 which extends generally in the machine directionand a rearwardly extending portion 155 which is tapered and which ispositioned at an angle to the direction of fiber movement. The airdeflector strip 154 possesses a configuration so that it overlies thebifurcated forming slot 144 and controls the flow of air thereinto. Thelower surface of the air deflector strips 154 is curved or tapered asshown in FIGS. 10 through 12 in order to properly control and direct thefiow of the air currents into the forming slots- 144. Open sections 157are provided in the air deflector plate 146 in order to permit the freeflow of air around the air deflector strips 154, through the fibrousweb, then through the foraminous supporting screen 169 and finallythrough the bifurcated forming slots 144 in the upper surface of theforming plate 138.

It will be appreciated that a fibrous web moving in the directionindicated in FIG. 9 willbe initially subdivided into a plurality ofindividual fibrous strips. This subdivision is accomplished by thedeflected air flow on both the right and left sides of the respectiveair deflector strips 154.

FIG. 10 illustrates the'division ofthe fibrous web into fibrous stripsat an early stage in the formation ofthe desired st-rand product. Thesubstantially vertical flow of the air at the left side of the airdeflector strip 154 passing through the web directed overthe slottedportion 149 holds that portion of the web in position. The deflectedportion of the air passing around theright side of the air deflectorstrip 154 and through the portion 151 of the forming slot divides thefibrous web into a plurality of fibrous strips and tends to roll theright side of each fibrous strip inwardly in spiral fashion to form astrand product S.

FIG. 11 shows an intermediate stage of thefor-mation of a strand productand discloses the rolling inwardly of the right side of the fibrousstrip.

FIG. 12 illustrates a substantially completed, spirallywrapped strandproduct. At this stage, the strand is sub stantially complete except fora slight compacting action when the strand passes the extreme end of therearwardly extending tapered portion 143 of the forming slot 144.

With reference to FIG. 9, it is to be noted that the bifurcated formingslot 144, in addition to tapering substantially in a Y-form, also slantsor leans to the right as viewed therein. In the event that the Y-form issymmetrically positioned with respectto the machine direction so that anupright Y is obtained, and the air deflector plate is also madesymmetrical so as to overlap both sides of the symmetrical Y-slots, twolaterally deflected air flows will result and both sides of thesubdivided fibrous strip will be curled inwardly by oppositely directedcomponents of force.

In this way a strand S is obtained which comprises two spirally-wrappedsections connected by the central portion of the fibrous strip, such asshown in FIG. 14. All the fibers therein are substantially parallelizedor aligned and the strand pro-duct S has excellent uniformity,substantially constant linear density and a minimum of thin, weakportions or thick, bulky sections. The fibers lie in their spiralsurfaces, although the number of spiral convolutions is less than in thecase of a singly wrapped strand product as illustrated in FIG. 13. Sucha strand is normally undesirable for use in normal textile operationsinasmuch as it possesses a weak center section. However, in certainspecial textile operations it is desirable and I I such a strand may beproduced by using a symmetrical Y-form rather than a slanted Y-forrn.

The invention will be further illustrated in greater detail by thefollowing specific examples. It should be understood, however, thatalthough these examples may describe in particular detail some of themore specific features of the invention, they are given primarily forpurposes of illustration and the invention in its broader aspects is notto be construed as limited thereto.

Example I The starting fibrous material is a 40-inch wide card web ofviscose ray-on fibers weighing about 100 grains per square yard andcontaining fibers having a length of about 1% inches and a denier of 1/2. The degree of fiber alignment is about 90%. The card web is draftedby being doffed from the doffing cylinder to the foraminous supportingscreen which is moving at a velocity of 40 yards per minute as comparedto the peripheral velocity of the doifing cylinder of yards per minute.The apparatus used is illustrated in FIG. 1.

The center-to-center spacing of the forming slots is 3 inches, asmeasured in a direction at right angles to the machine direction. Thelength of the forming slots is 8 inches, as measured in the machinedirection. The width of the forming slots at their forward position is-76 inch and the width of the forming slots at the rearward position isA inch. The air deflector strips are so positioned that their lowersurfaces have an angle of about 15 with respect to the upper surface ofthe forming plate. The center line of the forming slot has an angle ofabout 70 with respect to the cross-axis of the web so that the front endof each slot slightly overlaps the rear end of an adjacent slot.

The card web is subdivided into 13 separate strands which are spirallywrapped in cross section. Each strand weighs approximately 7 /2 grainsper linear yard of length. The strands are then twisted so that theresulting yarns have increased strength and can be manually handled andprocessed.

The resulting yarn has excellent uniformity and substantially constantlinear density. It is capable of being used in weaving operations.

Example 11 The procedures set forth in Example I are followedsubstantially as set forth therein with the exception that the startingmaterals comprise a blend of 50% by weight of the viscose rayon fibersused in Example I and 50% by weight of cotton having a staple length of1% inches. The degree of fiber alignment is about 90%.

The resulting yarn is comparable to the all viscoserayon yarn obtainedin Example 1, taking into account the expected differences due to thesubstitution of 50% by weight of the viscose ray-on by cotton. The yarnhas excellent uniformity and substantially constant linear density andcan be readily twisted into yarn. It is capable of being used in Weavingoperations.

Example III The procedures set forth in Example I are followedsubstantially as set forth therein with the exception that the startingmaterials comprise a blend of by weight of the viscose rayon fibers usedin Example I, 50% by weight of cotton having a staple length of 1%inches and 25% by weight of nylon 66 staple fibers having a length of 1/2 inches and a denier of 1 /2. The degree of fiber alignment is about90%.

The resulting yarn is comparable to the yarns obtained in Examples I andII, taking into account the expected differences due to the inclusion of25% by weight of nylon fibers.

Examples IV, V, and VI The procedures set forth in Example I arefollowed substantially as set forth therein with the exception that 12the angularity of the lower surface of the airv deflector strips withrespect to the forming plate is changed from the 15 value employedtherein.

In these examples, the angular relationship is 0, 10, and 20.

Strands are formed under all conditions and are capa bio of beingprocessed into yarns and used in weaving operations.

Examples VII,. VIII and IX The procedures set forth in Example I arefollowed substantially as set forth therein with the exception that thelinear surface velocity r'atio of the foraminous supporting member tothe dotting cylinder is changed from the 2:1 ratio employed therein.

In these examples, ratios of 1 /2:1, 2 /221 and 3%:1 are used. Theresulting degrees of fiber alignment are about 92% and 94%,respectively.

The yarn obtained using a ratio of' 1 /2 :1 is not as desirable as theyarns obtained using the higher velocity ratios, due most likely to thefact that the drafting of the card Web is less when lower velocityratios are used. Under conditions of low or no draft, many crossingfibers extend between the strands and cutting devices may be necessaryto provide for complete separation of the strands. Under conditions ofhigher drafting, the fibers are readily removed from the dofiingcylinder and transferred to the nylon foraminous screen in very highlydrafted form, usually with greater, than fiber alignment.

Example X 'The procedures of Example I are followed substantially as setforth therein except that the forming slots are /4 inch wide for theirfull length and are not tapered.

Satisfactory strands are prepared and are comparable to the strandsproduced in Example I.

Example XI The procedures of Example I are followed substantially as setforth therein withthe exception that the forming plateand air deflectorplate of FIG. 9 are used therein. The dimensions of the bifurcatedforming slots are as follows: the total length ofthe slot as measured inthe machine direction is 8 inches; the center-to-center distance betweenadjacent slots is 2 /8 inches; the spacing between the upper parallellegs of the bifurcated portion is 1%; inches; the length in the machinedirection of the upper parallel leg portions is 1 4 inches; and theangle taken by the center line of the bifurcated slot is approximately75.

The dimensions of the air deflector strips are as follows: the length ofthe strip is 8% inches; thewidth of the forward portion of the strip is1 inches; the length of the forward portion of the strip is 3 inches;the

width of the strip at the most rearward portion is inch;

and the angle taken by the center line of the rearward portion of thestrip is about 75.

The resulting yarn is comparable to the yarn obtained in Example I. Ithas excellent uniformity and substantially constant'linear density. Itis capable of being used 1n weaving operations.

Examples XII, XIII and XIV The procedures set forth in Example I arefollowed substantially as set forth therein with the exception that thestarting material weighs about 50, 150, and grains per square yard.Individual strands are produced therefrom and have excellent uniformityand substantially constant linear density. The strands are capable ofbeing twisted into yarns, with the lighter strands being capable ofbeing twisted to a higher and harder degree. The yarns are capable ofbeing used in weaving operations.

Example XV The procedures set forth in Example I are followedsubstantially as set forth'therein with the exception that appendedhereto.

13' the air deflector strips are removed and the air is permitted toflow directly into the forming slots without being deflected in any way.Strand formation is not accomplished and such an operation iscommercially impracticable for producing strands.

This example illustrates the necessity for the air deflector strips andthe creation of a laterally deflected air flow having the requiredcomponent of force to roll the divided fibrous strips inwardly to formthe desired unitary strands.

Although several specific examples of the inventive concept have beendescribed, the same should not be construed as limited thereby nor tothe specific values mentioned or constructions described but to includeother values and other constructions as set forth in the claims It isunderstood that any suitable changes, modifications and variations maybe made without departing from the spirit and scope of the invention.

What is claimed is:

1. The method of converting a fibrous layer contain- ;ing aligned fibersinto a plurality of unitary strands which comprises: causing a gaseousmedium to flow in the direction of and through said fibrous layer; anddeflecting saidv gaseous medium to divide it into a plurality ofportions prior to being passed through said fibrous layer, saidplurality of portions comprising certain spaced portions which exertcomponents of force on said layer in a direction generally perpendicularto the plane thereof to hold spaced areas of said layer in position andother spaced portions which are simultaneously deflected to divide saidlayer into a plurality of strips, each said deflected portion exerting acomponent of force on a fibrous strip in a direction generally parallelto the plane thereof and toward a respective holding portion, whereby atleast one edge of each strip is individually rolled inwardly upon itselfto form a plurality of compact unitary strands.

2. The method of converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: continuously movingsaid fibrous layer; causing. a gaseous medium to flow in the directionof and through said fibrous layer while it is being continuously moved;and deflecting said gaseous medium to divide it into a plurality ofportions prior to being passed through said fibrous layer, saidplurality of portions comprising certain spaced portions which exertcomponents of force on said layer in a direction generally perpendicularto the plane thereof to hold spaced areas of said layer in position andother spaced portions which are simultaneously deflected to divide saidlayer into a plurality of strips, each said deflected portion exerting acomponent of force on a fibrous strip in a direction generally parallelto the plane thereof and towarda respective holding portion, whereby atleast one edge of each strip is individually rolled inwardly upon itselfto form a plurality of compact unitary strands;

3. The method of converting a fibrous layer containing aligneddiscontinuous fibers into a plurality of unitary strands whichcomprises: drafting said fibrous layer to increase the fiber alignmentthereof in the long direction; passing a gaseous medium through saiddrafted fibrous layer; and deflecting said gaseous medium to divide itinto a plurality of portions prior to being passed through said draftedfibrous layer, said plurality of portions comprising certain spacedportions which exert components of force on said layer in a directiongenerally perpendicular to the plane thereof to hold spaced areas ofsaid layer in position and other spaced portions which aresimultaneously deflected to divide said layer into a plurality ofstrips,

each said deflected portion exerting a component of force rolledinwardly upon itself to form a plurality of compact unitary strands.

4. The method of converting a fibrous layer containing aligneddiscontinuous fibers into a plurality of unitary strands whichcomprises: drafting said fibrous layer at a drafting ratio of from about2:1 to about 4:1 to increase the fiber alignment thereof in the longdirection; passing a gaseous medium through said drafted fibrous layer;and deflecting said gaseous medium to divide it into a plurality ofportions prior to being passed through said drafted fibrous layer, saidplurality of portions comprising certain spaced portions which exertcomponents of force on said layer in a direction generally perpendicularto the plane thereof to hold spaced areas of said layer in position andother spaced portions which are simultaneously deflected to divide saidlayer into a plurality of strips, each saiddeflected portion exerting acomponent of force on a fibrous strip in a direction generally parallelto the plane thereof and toward a respective holding portion, whereby atleast one edge of each strip is individually rolled inwardly upon itselfto form a plurality of compact unitary strands.

5. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: vacuum means forpassing a gaseous medium through said layer; deflector means to dividesaid gaseous medium into a plurality of portions; said vacuum meanshaving openings therein so positioned with respect to said deflectormeans that spaced portions of said gaseous medium exert components offorce on said layer in a direction generally perpendicular to the planethereof to hold spaced areas of said layer in position and other spacedportions of said gaseous medium are simultaneously deflected to dividesaid layer into a plurality of strips; each said deflected portionexerting a component of force on a fibrous strip in a directiongenerally parallel to the plane thereof and toward a respective holdingportion, whereby at "least one edge of each strip is individually rolledinwardly upon itself to form a plurality of compact unitary strands.

6. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: vacuum means forpassing a gaseous medium through said layer; a plurality of deflectorplates to divide said gaseous medium into a plurality of portions; saidvacuum means having a plurality of openings therein so positioned withrespect to said deflector plates that spaced portions of said gaseousmedium exert components of force on said layer in a direction generallyperpendicular to the plane thereof to hold spaced areas of said layer inposition and other spaced portions of said gaseous medium aresimultaneously deflected to divide said layer into a plurality ofstrips; each said deflected portion exerting a component of force on afibrous strip in a direction generally parallel to the plane thereof andtoward arespective holding portion, whereby at least one edge of eachstrip is individually rolled inwardly upon itself to form a plurality ofcompact unitary strands.

7. Apparatus as defined in claim 6 wherein the deflector plates areangularly slanted with respect to the plane of the fibrous layer.

8. Apparatus as defined in claim 6 wherein the deflector plates areangularly slanted up to as high as about 30 with respect to the plane ofthe fibrous layer.

9. Apparatus as defined in claim 6 wherein the deflector plates areangularly slanted at an angle of from about 5 to about 20 with respectto the plane of the fibrous layer.

10. Apparatus as defined in claim 6 wherein the deflector plates and theopenings in the vacuum means are elongated and are angularly slantedwith respect to the fiber alignment of the fibrous layer.

11. Apparatus as defined in claim 10 wherein the leading edge of anopening in the vacuum means at least coincides with the trailing edge ofan adjacent opening,

as determined by a line extending in the direction of fiber alignment.12.; Apparatus as defined in claim 10 wherein the leading edge of anopening in the vacuum means overlaps the trailing edge of an adjacentopening, as determined by a line extending in the direction of fiberalignment 13. Apparatus for coverting a fibrous layer containing alignedfibers into a plurality of unitary strands which comprises: vacuum meansfor passing a gaseous medium through said layer; a plurality ofdeflector plates to divide said gaseous medium intd a plurality ofportions; said vacuum means having a plurality of elongated slottedopenings therein so positioned with respect to said deflector platesthat spaced portions of said gaseous medium exert components of force onsaid layei" in a direction generally perpendicular to the plane thereofto hold spaced areas of said layer in position and other spaced portionsof said gaseous medium are simultaneously deflected to divide said layerinto a plurality of strips; each said deflected portion exerting acomponent of force on a fibrous strip in a direction generally parallelto the plane thereof and toward a respective holding portion, whereby atleast one edge of each strip is individually rol'led inwardly uponitself to form a plurality of compact unitary strands.

14. Apparatus as defined in claim 13 wherein the deflector plates areWider and longer than the elongated slotted openings in the vacuum meansand prevent the direct access of gaseous medium thereto.

15. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: vacuum means forpassing a gaseous medium through said layer; a plurality of deflectorplates to divide said gaseous medium into a plurality of portions; saidvacuum means having a plurality of bifurcated openings therein sopositioned with respect to said deflector plates that spaced portions ofsaid gaseous medium exert components of force on said layer in adirection generally:

perpendicular to the plane thereof to hold spaced areas of said layer inposition and other spaced portions of said gaseous medium aresimultaneously deflected to divide said layer into a plurality ofstrips; each said deflected portions exerting a component of force on afibrous strip in a direction generally parallel to the plane thereof andtoward a respective holding portion, whereby at least one edge of eachstrip is individually rolled inwardly upon itself to form a plurality ofcompact unitary strands.

16. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: means forcontinuously moving said fibrous layer; vacuum means for passing agaseous medium through said layer while it is being continuously moved;deflector means to divide said gaseous medium into a plurality ofportions; said vacuum means having openings therein so positioned withrespect to said deflector means that spaced portions of said gaseousmedium exert components of force on said layer in a direction generallyperpendicular to the plane thereof to hold spaced areas of said layer inposition and other spaced portions of said gaseous medium aresimultaneously deflected to divide said layer into a V plurality ofstrips; each said deflected portion exerting a component of force on afibrous strip in a direction generally parallel to the plane thereof andtoward a respective holding portion, whereby at least one edge of eachstrip is individually rolled inwardly upon'itself to form a plurality ofcompact unitary strands.

17. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: a foraminoussupporting screen for moving said fibrous layer; vacuum means positionedunder said foraminous supporting screen for passing a gaseous mediumthrough said layer; deflector means to divide said gaseous medium into aplurality of portions; said vacuum means having openings therein sopositioned with respect to said deflector means that spaced portions ofsaid gaseous medium exert componentsof force on said layer in a di- Cirrection generally perpendicular to the plane thereof to hold spacedareas of said layer in position and other spaced portions of saidgaseous medium are simultaneously deflected to divide said layer into aplurality of strips; each said deflected portion exerting a component offorce on a fibrous strip in a direction generally parallel to the planethereof and toward a respective holding portion, whereby at least oneedge of each strip is individually rolled'inwardly upon itself to form aplurality of compact unitary strands. 18. Apparatus for converting afibrous layer containing aligned discontinuous fibers into a pluralityof unitary strands which comprises: means for drafting said fibrouslayer to increase the fiber alignment thereof in the long direction;vacuum means for passing a gaseous medium through said drafted fibrouslayer; deflector means to divide said gaseous medium into a plurality ofportions; said vacuum means having openings therein so positioned withrespect to said deflector means that spaced portions of said gaseousmedium exert components of force on said layer in a direction generallyperpendicular to the plane thereof to hold spaced areas of said layer inposition and other spaced portions of said gaseous mediumaresirnultaneously deflected to divide said layer into a plurality ofstrips; each said deflected portion exerting a component of force onefibrous strip in a direction generally parallel to the plane thereof andtoward a respective holding portion, whereby at least one edge of eachstrip is individually rolled inwardly upon itself to form a plurality ofcompact unitary strands.

19. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary'strands which comprises: a rotatable surfacefor carrying a fibrous layer of aligned fibers, vacuum means for passinga gaseous medium through said layer, a moving surface passing over saidvacuum means, suction means for transferring said layer from saidrotatable surface to said moving surface, a plurality of deflectorplates to divide said gaseous medium into a plurality of portions, saidvacuum means having openings therein so positioned with respect to saiddeflector plates that spaced portions of said gaseous medium exertcomponents of force on said layer in a direction generally perpendicularto the plane thereof to hold spaced areas of said layer in position andother spaced portions of said gaseous medium are simultaneouslydeflectedto divide said layer into a plurality of strips, each saiddeflected portion exerting a component of force on a fibrous strip in adirection generally parallel to the plane thereof and toward arespective holding portion, whereby at least one edge of each strip isindividually rolled inwardly upon itself to form a plurality of compactunitary strands.

20. Apparatus for converting a fibrous layercontaining aligned fibersinto a plurality of unitary strands which comprises: a rotatable surfacefor carrying a fibrous layer of aligned fibers, vacuum means for passinga gaseous medium through said layer, a moving surface passing over saidvacuum means, suction means spaced from about 0.005 inch to 0.125 inchfrom said rotatable surface for transferring said layer from saidrotatable surface to said moving surface, a plurality of deflectorplates to divide said gaseous medium into a plurality ofportions, saidvacuum means having openings therein so positioned with respect to saiddeflector plates that spaced portions of said gaseous medium exertcomponents of force on said layer in a direction generally perpendicularto the plane thereof to hold spaced areas of said layer in position andother spaced portions of said gaseous medium are simultaneouslydeflected to divide said layer into a plurality of strips, each saiddeflected portion exerting a component of force on a fibrous strip in adirection generally parallel to the plane thereof and toward arespective holding portion, whereby at least one edge of each strip isindividually rolled inwardly upon itself to form a plurality of compactunitary strands.

21. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: a rotatable surfacefor carrying a fibrous layer of aligned fibers, vacuum means for passinga gaseous medium through said layer, a moving surface passing over saidvacuum means, suction means spaced from about 0.015 inch to 0.030 inchfrom said rotatable surface for transferring said layer from saidrotatable surface to said moving surface, a plurality of deflectorplates to divide said gaseous medium into a plurality of portions, saidvacuum means having openings therein so positioned with respect to saiddeflector plates that spaced portions of said gaseous medium exertcomponents of force on said layer in a direction generally perpendicularto the plane thereof to hold spaced areas of said layer in position andother spaced portions of said gaseous medium are simultaneouslydeflected to divide said layer into a plurality of strips, each saiddeflected portion exerting a component of force on a fibrous strip in adirection generally parallel to the plane thereof and toward arespective holding portion, whereby at least one edge of each strip isindividually rolled inwardly upon itself to form a plurality of compactunitary strands.

22. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: vacuum means forpassing a gaseous medium through a fibrous layer, means for passing afibrous layer containing aligned fibers over said vacuum means, aplurality of deflector plates to divide said gaseous medium into aplurality of portions, said vacuum means having openings therein sopositioned with respect to said deflector plates that spaced portions ofsaid gaseous medium exert components of force on said layer in adirection generally perpendicular to the plane thereof to hold spacedareas of said layer in position and other spaced portions of saidgaseous medium are simultaneously deflected to divide said layer into aplurality of strips, each said deflected portion exerting a component offorce on a fibrous strip in a direction generally parallel to the planethereof and toward a respective holding portion, whereby at least oneedge of each strip is individually rolled inwardly upon itself to form aplurality of compact unitary strands.

23. Apparatus for converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: vacuum means forpassing a gaseous medium through a fibrous layer, means for passing afibrous layer containing aligned fibers over said vacuum means, aplurality of deflector plates to divide said gaseous medium into aplurality of portions, said vacuum means having a plurality of slottedopenings therein so positioned with respect to said deflector platesthat spaced portions of said gaseous medium exert components of force onsaid layer in a direction generally perpendicular to the plane thereofto hold spaced areas of said layer in position and other spaced portionsof said gaseous medium are simultaneously deflected to divide said layerinto a plurality of strips, each said deflected portion exerting acomponent of force on a fibrous strip in a direction generally parallelto the plane thereof and toward a respective holding portion, whereby atleast one edge of each strip is individually rolled inwardly upon itselfto form a plurality of compact unitary strands.

24. The method of converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: moving a fibrouslayer containing aligned fibers over a supporting surface, subjectingsaid fibrous layer while on said supporting surface to a vacuum therebycausing a gaseous medium to flow in the direction of and through saidfibrous layer and deflecting said gaseous medium to divide it into aplurality of portions prior to being passed through said fibrous layer,said plurality of portions comprising certain spaced portions whichexert components of force on said layer in a direction generallyperpendicular to the plane thereof to hold spaced areas in said layer inposition and other spaced portions whichare simultaneously deflected todivide said layer into a plurality of strips, each said deflectedportion exerting a component of force on a fibrous strip in a directiongenerally parallel to the plane thereof and toward a respective holdingportion, whereby at least one edge of each strip is individually rolledinwardly upon itself to form a plurality of compact unitary strands.

25. The method of converting a fibrous layer containing aligned fibersinto a plurality of unitary strands which comprises: forming a fibrouslayer containing aligned fibers on a rotatable surface, applying suctionto the fibrous layer on the rotatable surface and transferring saidlayer from said rotatable surface to a supporting surface, moving saidlayer over said supporting surface, subjecting said fibrous layer whileon said supporting surface to a vacuum thereby causing a gaseous mediumto flow in the direction of and through said fibrous layer and deflecting said gaseous medium to divide it into a plurality of portions priorto being passed through said fibrous layer, said plurality of portionscomprising certain spaced por tions which exert components of force onsaid layer in a direction generally perpendicular to the plane thereofto hold spaced areas in said layer in position and other spaced portionswhich are simultaneously deflected to divide said layer into a pluralityof strips, each said deflected portion exerting a component of force ona fibrous strip in a direction generally parallel to the plane thereofand toward a respective holding portion, whereby at least one edge ofeach strip is individually rolled inwardly upon itself to form aplurality of compact unitary strands.

26. The method of converting a fibrous layer into a plurality of unitarystrands which comprises: forming a fibrous layer on a rotatable surface,applying suction to the fibrous layer on the rotatable surface andtransferring said layer from said rotatable surface to a supportingsurface and simultaneously drafting the fibrous layer, moving saiddrafted layer over said supporting surface, subjecting said draftedfibrous layer while on said supporting surface to a vacuum therebycausing a gaseous medium to flow in the direction of and through saiddrafted fibrous layer and deflecting said gaseous medium to divide itinto a plurality of portions prior to being passed through said draftedfibrous layer, said plurality of portions comprising certain spacedportions which exert components of force on said layer in a directiongenerally perpendicular to the plane thereof to hold spaced areas insaid layer in position and other spaced portions which aresimultaneously deflected to divide said layer into a plurality ofstrips, each said deflected portion exerting a component of force on afibrous strip in a direction generally parallel to the plane thereof andtoward a respective holding portion, whereby at least one edge of eachstrip is individually rolled inwardly upon itself to form a plurality ofcompact unitary strands.

References Cited by the Examiner UNITED STATES PATENTS 1,765,571 6/1930Edson et a1. 2,274,424 2/1942 Miller l9150 2,274,425 2/ 1942 Miller19150 3,018,521 1/1962 Harmon 19150 3,135,023 6/1964 Kalwaites 19151 XFOREIGN PATENTS 25,629 2/1920 Denmark.

17,199 1903 Great Britain.

21,915 1902 Great Britain.

24,136 1902 Great Britain.

DONALD W. PARKER, Primary Examiner.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,230,584 January 25, 1966 Frank Kalwaites It is hereby certified thaterror appears in the above numbered patent requiring correction and thatthe said Letters Patent should read as corrected below.

Column 2 line 55 for "made-made" read man-made column 4 line 31 for"strating" read starting column 7 line 30 for "untiary" read unitarycolumn 9, line 19 after "is" insert less line 63, for "having" read havecolumn 11, line 26, for "5/6" read 5/8 Signed and sealed this 7th day ofFebruary 1967 SEAL) )RNEST W. SWIDER EDWARD J. BRENNER Lttesting OfficerCommissioner of Patents

1. THE METHOD OF CONVERTING A FIBROUS LAYER CONTAINING ALIGNED FIBERSINTO A PLURALITY OF UNITARY STRANDS WHICH COMPRISES: CAUSING A GASEOUSMEDIUM TO FLOW IN THE DIRECTION OF AND THROUGH SAID FIBROUS LAYER; ANDDEFLECTING SAID GASEOUS MEDIUM TO DIVIDE IT INTO A PLURALITY OF PORTIONSPRIOR TO BEING PASSED THROUGH SAID FIBROUS LAYER, SAID PLURALITY OFPORTIONS COMPRISING CERTAIN SPACED PORTIONS WHICH EXERT COMPONENTS OFFORCE ON SAID LAYER IN A DIRECTION GENERALLY PERPENDICULAR TO THE PLANETHEREOF TO FLECTED PORTION EXERTING A COMPONENT OF FORCE ON A FIBROUSSTRIP IN A DIRECTION GENERALLY PARALLEL TO THE PLANE THEREOF AND TOWARDA RESPECTIVE HOLDING PORTION, WHEREBY AT LEAST ONE EDGE OF EACH STRIP ISINDIVIDUALLY ROLLED INWARDLY UPON ITSELF TO FORM A PLURALITY OF COMPACTUNITARY STRANDS.
 5. APPARATUS FOR CONVERTING A FIBROUS LAYER CONTAININGALIGNED FIBERS INTO A PLURALITY OF UNITARY STRANDS WHICH COMPRISES:VACUUM MEANS FOR PASSING A GASEOUS MEDIUM THROUGH SAID LAYER; DEFLECTORMEANS TO DIVIDE SAID GASEOUS MEDIUM INTO A PLURALITY OF PORTIONS; SAIDVACUUM MEANS HAVING OPENINGS THEREIN SO POSITIONED WITH RESPECT TO SAIDDEFLECTOR MEANS THAT SPACED PORTIONS OF SAID GASEOUS MEDIUM EXERTCOMPONENTS OF FORCE ON SAID LAYER IN A DIRECTION GENERALLY PERPENDICULARTO THE PLANE THEREOF